JP3345024B2 - Coil winding machine and coil winding method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a coil winding machine and a coil winding method for winding a rectangular wire, which is a kind of filament, in a vertical state.

2. Description of the Related Art Japanese Patent Application Laid-Open No. 4-75303 published in Japan discloses a coil winding machine for winding a strip-shaped rectangular wire having a rectangular cross section in a vertical state. In this coil winding machine, a rotating shaft member to which one short side of a rectangular wire is abutted, and one long surface of the rectangular wire abutted on the end surface (support surface) while being inserted through the rotating shaft member. A cylindrical bush, and a pressing roller pressed against the other short surface of the rectangular wire so as to sandwich the rectangular wire between the rotating shaft member, and the pressing roller and the bush are forcibly disengaged. By rotating, the flat wire is sequentially wound vertically around the rotating shaft member. According to this coil winding machine, the rectangular wire is vertically wound, so that a relatively thin coil can be formed.

The coils wound by the coil winding machine have long sides of the flat wire facing each other. However, in such a coil, the interval between the rectangular wires (the interval in the direction of the central axis of the coil) is widened due to the springback of the rectangular wire after winding, and the thickness dimension is increased. That is,
As described above, the coil wound by the conventional coil winding machine has a problem that the thickness of the coil cannot be sufficiently reduced because the coils are spaced from each other in the axial direction. Such a problem of the coil has become a very important problem in the field of electronic devices in which demands for miniaturization and thinning are severe. At the same time, the conventional coil has a problem that the winding diameter becomes large after winding due to springback.

Further, in the conventional coil winding machine, since both ends of the coil are left unwound in a straight line, it is necessary to cut the straight line portion as necessary in a later step. That is, when a conventional coil winding machine is used, a step of cutting the winding start portion and the winding end portion is separately required, so that there is a problem of an increase in cost due to many steps related to coil manufacturing. .

DISCLOSURE OF THE INVENTION A first object of the present invention is to provide a coil winding machine and a coil winding method capable of realizing a small and thin coil shape by suppressing springback after winding of a filament material. It is to provide.

In order to achieve such an object, in the present invention, as a means relating to the coil winding machine, a means of performing winding while plastically deforming the filament material is employed.

Further, in the present invention, as specific means for plastically deforming and winding such a wire material, the wire material is brought into contact with a core member, and the wire material is wound into a pair of windings. The jig is clamped from both sides by the pressing force that plastically deforms the wire,
A means is adopted in which one of the winding jigs is driven to rotate to wind the winding jig around the peripheral surface of the core member.

Further, in the present invention, as a specific means for plastically deforming and winding the wire material in this manner, the distal end portion of the wire material is sandwiched between the opposing surfaces in a press-contact state, and either one of the opposed surfaces faces the opposite side. A pair of winding jigs that are rotationally driven in the plane, and a winding jig that is rotationally driven and a winding that is not rotationally driven along the rotation center of the winding jig that is rotationally driven A core member inserted into a jig provided in the jig; and a peripheral surface of the core member movably provided along the rotation center with respect to a winding jig which is not driven to rotate. And the middle jig sandwiching the wire material wound around in a press-contact state between the facing surface of the winding jig that is driven to rotate and the facing jig. The wire is wound around the peripheral surface of the core member using the pressing force of the surface and the middle jig against the wire as the pressure to plastically deform the wire. To adopt the means that.

On the other hand, in the present invention, as a means related to the coil winding method, means for winding the wire while plastically deforming the wire is adopted.

In the present invention, in the means relating to such a coil winding method, the wire material is brought into contact with the core member, and the wire material is wound from both sides by a pair of winding jigs. More specifically, a more specific means is employed in which the material is sandwiched by a pressing force for plastically deforming, and one of the winding jigs is rotated to be wound around the peripheral surface of the core member.

By adopting such a means, in the present invention, the wire is wound while being plastically deformed, so that it is possible to suppress springback after the wire is wound, and thus change the coil shape. Can be suppressed as much as possible.

For example, when a flat wire is used as a linear material and the flat wire is wound in a vertical state, the coil shape can be reduced in thickness because springback is suppressed.
In addition, since the coil diameter is prevented from increasing, the coil shape can be reduced in size. Therefore, it is possible to manufacture a coil suitable for use in an electronic device that is strongly required to be small and thin.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing a configuration of a coil winding machine according to an embodiment of the present invention.

FIG. 2 is a perspective view illustrating a configuration of a winding jig in the coil winding machine according to the embodiment of the present invention.

FIG. 3A is a plan view showing a detailed configuration of a winding jig in the coil winding machine according to the embodiment of the present invention.

FIG. 3B is a side view showing a detailed configuration of a winding jig in the coil winding machine according to the embodiment of the present invention.

FIG. 4 is a perspective view showing a positional relationship between the winding jig and the flat wire at the start of winding in the embodiment of the present invention.

FIG. 5 is a first process diagram illustrating a winding process according to the embodiment of the present invention.

FIG. 6 is a second process diagram illustrating a winding process according to the embodiment of the present invention.

FIG. 7 is a third process diagram illustrating a winding process according to the embodiment of the present invention.

FIG. 8 is a fourth process diagram illustrating a winding process according to the embodiment of the present invention.

FIG. 9 is a front view showing a winding state of a flat wire in the embodiment of the present invention.

FIG. 10 is a perspective view of a coil wound according to the embodiment of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a best embodiment of the present invention will be described.

First, the overall configuration of the coil winding machine according to the present embodiment will be described with reference to FIG. In FIG.
Is a rectangular base, and is arranged, for example, such that its long side is along the X-axis direction of the coordinate axes. On the base 1, an L-shaped plate having a rectangular shape, a long side of which is arranged along the X-axis direction, and an upright portion 2a protruding in the Z-axis direction at its rear end is provided. A base member 2, a movable support 4 movable in the X-axis direction by a rail 3 at a position separated from the base member 2, a cylinder 5 for moving the movable support 4 in the X-axis direction, and a rectangular wire A A wire guide 6 slidably supported is provided.

The base member 2 has X on its upper surface via a rail 7.
An L-shaped auxiliary base member 8 that moves in the axial direction is provided, and a cylinder 9 that moves the auxiliary base member 8 in the X-axis direction is provided in the upright portion 2a. The auxiliary base member 8 is formed in a shape similar to that of the base member 2 and includes an upright portion 8a to which the rod tip of the cylinder 9 is fixed. A head member 10 that moves in the direction is provided, and a pressing cylinder 11 that moves the head member 10 in the X-axis direction is fixed via a bracket 12.

Further, the auxiliary base member 8 includes a core front and rear cylinder 8b. A rod-shaped core member 13 is fixed to the distal end of the rod of the core front and rear cylinder 8b via a connecting member 14. The connecting member 14 is for connecting the core member 13 to the rod of the core front / rear cylinder 8b in a rotatable manner. The core member 13 has an X-axis direction as an axis and is inserted into the head member 10, and is moved in the X-axis direction, that is, the axis direction by the core front-rear cylinder 8b. I have.

The head member 10 includes a rotary jig support mechanism 15 in which the core member 13 is inserted and rotatably supported, and a spindle motor 16 for driving the rotary jig support mechanism 15 to rotate.
, And a chuck opening / closing cylinder 17, and a rotary jig R is mounted. That is,
The core 13 is inserted through the center of rotation of the rotary jig R. The rotary jig support mechanism 15 includes a cylindrical rotary support 18 and a hollow cylindrical chuck 19 provided on an end surface (back surface) of the rotary support 18. The rotary support 18 supports the rotary jig R, and is coupled via a belt 20 to a pulley 16a attached to a shaft of the spindle motor 16. The rotary support 18 rotates the rotary jig R by being rotationally driven by the pindle motor 16.

The chuck 19 couples / disengages the core member 13 with / from the rotating support 18 and has a plurality of splines formed in the outer peripheral surface thereof in the X-axis direction. The chuck 19 has a core member formed by moving an annular tightening member 22 attached to the rod end of the chuck opening / closing cylinder 17 via a long support 21 in the X-axis direction along a spline. 13 is coupled / disengaged to a rotating support 18. In the case of FIG.
When the core member 13 moves in the positive direction of the X-axis, the core member 13 is coupled to the rotary support 18. When the fastening member 22 moves in the negative direction of the X-axis, the core member 13 is released from the rotary support 18. .

On the other hand, the moving support 4 supports the end surface (front) of the cylindrical fixing jig S so as to face the end surface (front) of the rotating jig R, and holds the fixing jig S in the X-axis direction. A pressurizing cylinder 23 for pressurizing in the direction is provided. The fixing jig S is mounted on the movable support 4 via a spring 24 so as to be movable in the X-axis direction. The tip of the rod of the pressure cylinder 23 is attached to the end surface (back surface) of the fixing jig S via the bracket 25, and the fixing jig S is operated by the operation of the pressure cylinder 23.
Is pressed in the negative direction of the X axis. The cylindrical jig Sa is inserted into the axis of the fixing jig S. The end surface (rear surface) of the middle jig Sa is fixedly supported by the movable support 4, and the other end surface (front surface) faces the core member 13.

Here, the flat wire A is a flat linear material, and its cross section is a rectangle having a short surface a1 and a long surface a2. Such a flat wire A is supplied from the wire feeder 26, and is inserted between the rotating jig R and the fixing jig S which are supported and opposed by the wire guide 6. It is supposed to be. The rotating jig R and the fixing jig S constitute a winding jig.

Next, a detailed configuration of the rotating jig R, the fixing jig S, and the middle jig Sa will be described with reference to FIGS.

The middle jig Sa has a cylindrical main body s1 and a front s2 of the main body s1.
A core insertion hole s3 into which the tip of the cylindrical core member 13 is inserted, i.e., a hole formed at the center of the core member, and a peripheral surface s4 of the main body s1.
And a flange portion s5 formed at a fixed length from the front surface s2 along the axis L. A surface (guide surface) that is continuous from the front s2 to the tip s6 of the flange s5
s7 is formed so as to be slightly inclined toward the back surface s8 of the main body s1 with respect to the front surface s2. In addition, the guide surface s7 and the front
The width of s2 is set slightly wider than the width b of the long surface a2 of the flat wire A.

The fixing jig S is for inserting the middle jig Sa formed in this way, and includes, for example, a cylindrical main body s9 and a hole formed along the axis L at the center of the main body s9. There is a winding accommodating hole s10 in which the middle jig Sa is inserted and a peripheral surface s12 at a position corresponding to the front surface s11 of the main body s9 and the collar s5.
And a wire introduction window s13 having a constant depth and extending in the direction of the axis L from the wire winding receiving hole s10.

The front surface s11 of the fixing jig S (the surface facing the rotating jig R) is not a single plane but formed as follows. That is, of the ring-shaped front surface s11, a fan-shaped surface portion s14 having a constant angle from the wire introduction window s13 about the axis L in this figure is formed so as to be orthogonal to the axis L, and other surface portions s15 are Arrow to sector s14
It is formed so as to smoothly retreat sequentially along k1. That is, a step s17 having a predetermined depth is formed at the side s16 of the sector-shaped surface s14.

The rotating jig R is formed as follows with respect to the fixing jig S formed as described above. That is, the rotary jig R is, for example, a cylindrical main body part r1 and a hole formed in the direction of the axis L at the center of the main body part r1.
It is formed of an insertion hole r2 through which the hole 13 is inserted, and a guide groove r4 formed on the front surface r3 of the main body r1 (the surface facing the fixing jig S). The guide groove r4 has a short surface a1 of the flat wire A and a core member.
3A is a groove into which the front end portion enters in a state of contact with the peripheral surface of 13 (vertical state), and is constant from the upper portion of the insertion hole r2 to the outer peripheral surface r4 of the main body portion r1 at the front surface r3 as shown in FIG. 3A. It is formed so as to be inclined and deep. Further, the depth of the guide groove r4 in the outer peripheral surface r5 is formed slightly larger than the dimension of the short surface a1 of the flat wire A.

The front surface r3 of the rotary jig R is not a single plane, but
Is formed so as to be orthogonal to the axis L at a predetermined angle from the guide groove r4 with respect to the guide groove r4.
Are formed so as to gradually and smoothly retreat along the arrow k2 with respect to the sector-shaped surface portion r6. That is, a step r9 having the same depth as the step s17 is formed at the side r8 of the sector-shaped surface r6. That is, the front surface r3 of the rotating jig R is in contact with the front surface s11 of the fixing jig S with the rectangular wire A interposed therebetween.

The rotating jig R and the fixing jig S thus formed are
As shown in FIG. 4, the flat wire A is guided from the wire introduction window s13 to the guide groove r4, and the front faces s11 and r3 are brought into contact with each other so as to sandwich the flat wire A. It is held vertically on the peripheral surface of the member 13. In this state, the front surface s2 of the middle jig Sa and the guide surface s7 are in contact with one long surface a2 of the flat wire A.

Although the configuration of the coil winding machine of the present embodiment has been described above, the cylinders 5 and 9 serving as driving means, the core front and rear cylinders 8b, the pressurizing cylinders 11 and 23, and the chuck opening / closing cylinder 17 are provided.
The spindle motor 16 is controlled and driven by a control device (not shown). In addition, the supply of the flat wire A is adjusted by a filament material supply device (not shown).

Next, a coil winding method using the coil winding machine will be described with reference to FIGS.

First, in the present coil winding machine, the position of the rectangular wire A in the X-axis direction is kept constant as shown in FIG. 3 by being slidably supported by the wire guide 6. In this state, the cylinders 5 and 9 are operated to rotate the jig R
And the fixing jig S are moved so as to sandwich the rectangular wire A.

That is, when the cylinder 5 is actuated and the movable support 4 is moved on the rail 3 in the negative direction of the X-axis, a part of the front surface s11 of the fixing jig S (a part facing the guide groove r4) and the middle jig The guide surface s7 of Sa is brought into contact with one long surface a2 of the flat wire A. When the cylinder 9 is actuated to move the auxiliary base member 8 on the rail 7 in the positive X-axis direction and the core front and rear cylinders 8b are operated, the core member
13 is inserted into the core insertion hole s3 of the center jig Sa, and the end of the flat wire A enters the guide groove r4, and the bottom surface of the guide groove r4 and the front surface r3 of the rotary jig R are inserted. Part (guide surface of middle jig Sa
s7) is brought into contact with the other long surface a2 of the flat wire A.

In the state where the rectangular wire A is sandwiched by the fixing jig S, the middle jig Sa, and the rotating jig R, the inclination of the guide surface s7 and the depth of the guide groove r4 have a constant inclination. The distal end is slightly inclined toward the rotary jig R with respect to the axis L. In this state, the flat wire A is slidable with respect to the various surfaces (contact surfaces) in the contact state.

In this state, by successively operating the pressurizing cylinders 11 and 23, the long surfaces a2 of the flat wire A are pressed by the various contact surfaces with a constant pressing force. The pressing force is
This force is in a direction orthogonal to the longitudinal direction (winding direction) of the rectangular wire A, and acts as a side pressure on the rectangular wire A. The lateral pressure (pressure contact force) is set according to the type of the flat wire A, and is set to a pressure slightly exceeding the elastic limit of the flat wire A, that is, a pressure capable of plastically deforming the flat wire A. .

FIG. 5 is a process diagram showing a state in which lateral pressure is applied to the flat wire A (the initial state of the winding process). In this state, the spindle motor 16 is operated and the rotating jig R
Is rotated clockwise. At this time, since the supply of the flat wire A is stopped by the filament material supply device 26, the tip of the flat wire A, that is, the portion of the flat wire A inserted into the guide groove r4 is wound as shown in FIG. Is wound in accordance with the rotation angle of the rotary jig R. Since the end of the flat wire A enters the guide groove r4 as described above,
Since r6 protrudes from the guide groove r4 in the positive direction of the X axis, it is reliably rotated and wound around the peripheral surface of the core member 13. Here, the flat wire A is wound around the core member 13 while being plastically deformed by a lateral pressure exceeding the elastic limit by the various contact surfaces.

Then, as shown in FIG. 7, the entire end of the flat wire A is wound around the peripheral surface of the core member 13 in a state where the rotary jig R has rotated half a turn. That is, in this embodiment, the length of the distal end portion of the flat wire A is set to a length wound around the half circumferential surface of the core member 13. In this state, the chuck opening / closing cylinder 17 is operated to close the chuck 19. As a result, the rotary jig R and the core member 13 are brought into a connected state, and thereafter, the core member 13 rotates simultaneously with the rotary jig R.

Subsequently, the rotating jig R is rotated together with the core member 13, and the flat wire A is sent out from the filament supply device 26 in synchronization with the rotation of the rotating jig R. The rectangular wire A is sandwiched between the front surface r3 of the rotary jig R and the front surface s2 of the middle jig Sa. The front of this rotary jig R
The pressing force (lateral pressure) applied to the rectangular wire A by r3 and the front surface s2 of the middle jig Sa also changes the rectangular wire A similarly to the lateral pressure applied to the rectangular wire A by the rotating jig R and the fixing jig S. The pressure is set so that plastic deformation occurs.
Is wound around the core member 13 while being plastically deformed.

Here, the position of the wire rod guide 6 in the X-axis direction, that is, the supply position of the flat wire A, is constant.
The position of the movable support 4 in the axial direction is set at a fixed position by the cylinder 5. However, since the wound rectangular wire A is sequentially accommodated in the winding accommodating hole s10 in accordance with the rotation of the rotary jig R, the position of the rotary jig R in the X-axis direction is as shown in FIG. The fixing jig S is sequentially displaced in the negative X-axis direction, and at the same time, the position of the fixing jig S is also sequentially displaced in the negative X-axis direction.

When the rectangular wire A is wound a predetermined number of times in this manner, the rectangular wire A is cut by a cutting device (not shown) at the supply side of the rectangular wire A, for example, at the entrance of the wire introduction window s13, and the rotating jig R is further rotated. Wind up the remaining flat wire A. When all the rectangular wires A are wound, the pressure contact by the pressurizing cylinders 11 and 23 is released, and the front and rear cylinders 8b of the core are actuated to remove the core 13 from the fixing jig S. Further, when the cylinders 5 and 9 are operated, the fixing jig S and the rotating jig R are separated from each other, and the coil in the winding accommodating hole s10 is taken out.

FIG. 10 shows a coil C manufactured by the above winding process.
It is a perspective view of. According to such a method of manufacturing the coil, the rectangular wire A is wound while being plastically deformed by the lateral pressure applied to the long surface a2 of the rectangular wire A, so that the springback generated after the completion of the winding is suppressed. Therefore,
Since the distance between the wound rectangular wires A is reduced, a coil having a small coil thickness d can be manufactured.

Note that the present invention is not limited to the above embodiment, and for example, the following modified examples also belong to the scope of the present invention.

(1) In the above embodiment, the middle jig Sa is fixed to the moving support 4 so that the fixing jig S can be moved in the X-axis direction with respect to the middle jig Sa. S is the moving support 4
, And the jig Sa is attached to the movable support 4 via an elastic member such as a spring. In this case, the flat wire A wound around the core member 13 is plastically deformed and wound while receiving the side pressure from the rotating jig R and the elastic member.

(2) In the coil winding step, as shown in FIG.
The winding start portion c1 and the winding end portion c2 of the coil are completely wound in a ring shape. However, at the start of the rotation of the rotary jig R, the rotary jig R and the core member 13 are simultaneously rotated in the coupled state, and the holding force of the flat wire A of the wire guide 6 is relaxed, so that the guide groove r4 is formed. The tip of the rectangular wire A inserted into the wire is maintained in a straight body without being wound. Further, by taking out the coil in a state where the supply side of the flat wire A is cut by the cutting device, the rear end of the flat wire A also becomes a rectangular body. According to such a winding process, straight lead wires are formed at both ends of the coil.

(3) In the above-described embodiment, the position of the wire guide 6 in the X-axis direction, that is, the supply position of the flat wire A is constant, and the rotating jig R and the fixing jig S together with the winding of the flat wire A are X-axis negative. It is configured to move in a direction. The above modification (1)
Then, the middle jig Sa moves in the X-axis positive direction together with the winding of the flat wire A. However, the wire guide 6 can be configured to be movable in the X-axis direction, and the rotating jig R, the fixing jig S, or the middle jig Sa can be fixed as much as possible. In this case, a moving mechanism of the wire guide 6 is required.

(4) In the above embodiment, the embodiment relating to the coil winding machine for the rectangular wire A and the winding method thereof has been described. However, the essential technical idea of the present invention is to suppress springback after winding as much as possible. In addition, the type of the wire material is not limited to the rectangular wire A because the wire material is wound while being plastically deformed. It is also possible to apply a round wire or the like usually used for coil production. However, in this case, it is necessary to change the shape of each front surface of the winding jig (the rotating jig R and the fixing jig S) according to the shape of the linear material.

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) H01F 41/06

Claims (8)

(57) [Claims] A wire material is brought into contact with a core member, and the wire material is sandwiched between a pair of winding jigs by a pressing force for plastically deforming the wire material from both sides. A coil winding machine characterized in that a winding jig is driven to rotate to wind around a peripheral surface of a core member. 2. A pair of winding jigs, each of which opposes the distal end of a wire material in a press-contact state by each of the opposing surfaces, and one of which is rotatably driven in the opposing surfaces. A winding core member that is inserted along the rotation center of the winding jig through the winding jig that is driven to rotate and the middle jig provided in the winding jig that is not driven to rotate; The non-driven winding jig is provided movably along the rotation center and opposes the winding jig that rotationally drives the wire wound around the peripheral surface of the core member. The jig sandwiched in a press-contact state between the wire jig and the surface of the wire jig which is rotationally driven. A coil winding machine characterized in that a wire material is wound around a peripheral surface of a core member as pressure. 3. The coil winding machine according to claim 1, wherein a guide groove into which the leading end of the wire material enters is formed in the winding jig that is driven to rotate. 4. When the supply of the filament material is stopped at the start of winding, and when the leading end of the filament material is wound around the peripheral surface of the core member,
The coil winding machine according to any one of claims 1 to 3, further comprising a wire feeder that feeds the wire in synchronization with the rotation of the winding jig that is driven to rotate. 5. The coil winding machine according to claim 1, wherein the wire material is a flat wire, and the flat wire is wound in a vertical state. 6. A wire material is brought into contact with a core member, and the wire material is sandwiched from both sides by a pair of winding jigs by a pressing force for plastically deforming the wire material. A coil winding method, wherein a winding jig is driven to rotate to wind around a peripheral surface of a core member. 7. The supply of the filament material is stopped at the start of winding, the leading end of the filament material is also wound around the peripheral surface of the core member, and the rear end of the filament material at the end of winding. 7. The coil winding method according to claim 6, wherein the step (c) is also wound around the peripheral surface of the core member. 8. The coil winding method according to claim 6, wherein the linear material is a flat wire, and the flat wire is wound in a vertical state.